Wet Scrubber Assembly for Mold-Resistant Paper Production
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Solution Overview
Problem
Existing methods for producing mold-resistant gypsum panels are inefficient and costly, as antimicrobial additives often fail to be effectively incorporated into the paper during the manufacturing process, leading to microbial growth issues and operator exposure to harmful fumes and particles.
Innovation Solution
A system and method utilizing a wet scrubber assembly with a venturi scrubber and separator to remove particulate-laden air from the paper manufacturing line, allowing for the efficient application and collection of antimicrobial additives at the calender stack or rewinder stations, reducing airborne particulate and improving air quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If antimicrobial additives are applied at the wet end of the paper making process, then mold resistance is achieved, but the bulk of the biocide fails to be incorporated into the paper and is lost during water drainage
Solution Approach 1:
The biocide is applied to the paper at the wet end of the paper making process, before the paper is fully formed and before water drainage occurs. This preliminary application allows the biocide to be incorporated into the paper matrix during the forming stage, ensuring both mold resistance and efficient incorporation without loss during subsequent drainage operations.
2Loss of substance
If antimicrobial additives are applied at the calender stack or rewinder stations, then material loss is minimized, but airborne particulate and fumes expose operators to harmful substances
Solution Approach 1:
The harmful airborne particulate and fumes generated during biocide application at the calender stack or rewinder stations are extracted and removed from the operational area using a exhaust collection assembly with a hood. This extraction system captures the contaminants at the source, preventing operator exposure while allowing the biocide application process to continue with minimized material loss.
Solution Approach 2:
An exhaust collection assembly with a hood acts as an intermediary between the biocide application process and the operator environment. The hood captures and removes harmful airborne substances, serving as a protective barrier that allows the beneficial biocide application to proceed while preventing harmful exposure to operators.
3Ease of manufacture
If existing methods are used to produce mold-resistant paper, then the process is simple, but the production is inefficient and costly due to material losses and rework
Solution Approach 1:
The system incorporates feedback mechanisms where the exhaust collection assembly monitors and collects information about the biocide application process and airborne contaminants. This feedback allows for optimization of the application rate and timing, improving production efficiency by reducing material losses and minimizing the need for rework, while maintaining process simplicity through integrated control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves at least 95% removal of antimicrobial particulate matter, enhancing the production of mold-resistant paper that effectively suppresses microbial growth and reduces operator exposure to irritants, while providing cost savings by minimizing material losses.
Implementation Method 1
The venturi scrubber is adapted to receive a flow of particulate-laden air from the operational area via the exhaust collection assembly. The venturi scrubber is in fluid communication with a source of liquid to pass the flow of particulate-laden air through the liquid to remove particulate from the flow of air
Implementation Method 2
The separator is adapted to separate liquid with entrained particulate from the flow of the exhaust/liquid mixture to produce a cleaned exhaust air stream
Data Source
AI summary
Embodiments of a system and a method for preparing mold-resistant paper comprising a wet scrubber assembly in fluid communication with at least one collection plenum disposed at an operational area of a paper manufacturing line. The wet scrubber assembly can be operated to draw a stream of exhaust air from the operational area of the paper manufacturing line through the wet scrubber assembly to remove particulate from the exhaust stream. Such systems and methods can be used to produce mold-resistant paper by coating a paper with an antimicrobial composition including at least one antimicrobial additive at the calendering stage. The collection plenum can be placed in proximate relationship with the calendering stack such that the amount of antimicrobial additive particulate in the air at the calendering stage is reduced. The mold-resistant paper can be used in a gypsum panel.